FD100 分
FD100 分
FD100 分
Company Introduction
² wellhead tools
Firmly holding the principle of “Customer First”, RG PETRO-MACHINERY (GROUP)
CO. LTD has established a professional service organization in all the domestic major
oilfields to provide all-around after-sales services ranging from equipment installation,
debugging, maintenance, training and spare parts supply. The products of RG
PETRO-MACHINERY (GROUP) CO. LTD are in great demand in all the oilfields of China
and have been exported to about 30 countries and regions across the world such as, The
United States of America, Canada, Mexico, Turkmenistan, Kazakhstan, India, Iraq, Egypt,
Sudan, Nigeria and Venezuela.
RG GROUP warmly welcomes customers home and abroad for contact and
cooperation to create a shining success for all!
RG GROUP will be your cordial friend and desirable partner forever.
Preface
Nanyang RG Petro-machinery (Group) Co. Ltd. thanks you for choosing transfer case
developed and produced by our company.
TheXJ350 workover rig are both self-propelled drilling rig, which is suitable for oil,
gas and well drilling operation. In order to make sure that the equipment operates well and
the operator is safe, so when you operate this equipment, please make sure that you are
accordance with the operating regulation and maintenance programs that is formulated by
this instruction. Before you operate this rig for first time, the operator should know all the
technical documents, operating instruction and regulation well, follow operating
procedure and notice matters, do some maintenance for equipment regularly, if any
abnormal appears, the equipment must be stopped and be checked for the reasons, after all
malfunctions are expelled, then the equipment could operate again, the correct operating
procedure could make its performance displaying sufficiently and extend its service life.
This instruction main introduces the main technical parameters, main structure,
working principle, function, operation of engagement and disengagement device, operation
of the front and rear axle engagement and disengagement device, maintenance of the
transfer case. It is used for equipment managers, operators, and maintenance personnel.
As the structure of FD100 transfer case is very complex, this manual can’t cover
everything. If the user meets the situation not mentioned in this manual, please inform the
technical service department of RG at once, and we will provide technical support or
dispatch personal for after-sale service.
Any operation, management, maintenance and repair personnel of the product must
know very well of the relative content of the instruction and abide by the regulation related
to operation, management, maintenance and repair, especially for the content such as safety
warning and attention given by this instruction, as well as common-sense safety regulations
and matters needing attention prompted by national law, regulation, industrial regulation, so
as to avoid human injury and damage of the equipment.
The instruction could not list all safety warning information in details, so any method I
is selected for operation, it must be ensured that it will neither endanger the human safety
nor damage the equipment.
Correct maintenance is the key factor for safe and reliable operation of the product.
The maintenance personnel shall maintain the equipment according to the method
introduced in the instruction manual.
The correct repair of the product and replacement of the components manufactured by
origin factory are key factors for safe and reliable operation of the equipment. The user must
maintain and replace the component within the scope authorized by the manufacturer.
When the user has special requirement for the product, the configuration of the product
may differ from the instruction manual, and the actual configuration of the product shall
govern.
Please read carefully when the instruction manual uses the following title and mark!
Warning: Used for the situation where incorrect operation procedures and methods
may lead to human injuries.
Caution: Used for the situation where there may be human injuries and damage of
equipment if the operation procedure and method is not observed strictly.
Note: Used for the situation where there is need for attention or independent
explanation.
Contents
Ⅰ. Main Structure and Working Principle ...................................................................... 1
Ⅱ. Model and Main Function Specification ..................................................................... 1
2.1 Model:........................................................................................................................ 1
2.2 Main function specification ........................................................................................ 1
Ⅲ. Installation and Adjustment ........................................................................................ 1
3.1 Installation ................................................................................................................. 1
3.2 Adjustment ................................................................................................................. 2
Ⅳ. No-Load Test ................................................................................................................ 2
4.1 Elimination Run ......................................................................................................... 2
4.2 No-load test ................................................................................................................ 2
4.3 Loading test................................................................................................................ 3
Ⅴ. Inspection and Maintenance ....................................................................................... 3
5.1 The inspection for gear oil .......................................................................................... 3
5.2 The inspection of fastener ........................................................................................... 3
5.3 The test item of cover-off ........................................................................................... 3
5.4 Inspection of transfer case's work condition ................................................................ 4
5.5 Maintenance ............................................................................................................... 4
5.6 Maintenance of Storage .............................................................................................. 4
Ⅵ. Lubrication .................................................................................................................. 4
6.1 Period of replace oil ................................................................................................... 4
6.2 The oil sites like the following Fig: ............................................................................ 5
Ⅶ. The Operation of Engaging/disengaging device ......................................................... 5
Ⅷ. Common Troubleshooting ........................................................................................... 6
Ⅸ.Quick-Wear Parts list ................................................................................................... 6
9.1 Bearing ......................................................................................................................... 6
9.2 Oil seal ....................................................................................................................... 6
Ⅹ.Attached drawings ........................................................................................................ 6
2.1 Model:
FD 100
3.2 Adjustment
1. Gear adjustment
The way is: reduce or add the number of gasket at the two ends of the axles, insure the
big coincidence of the gears
2. The space of flank of tooth: the space should be controlled at 0.21-0.32mm
3. Adjustment of the bearing
The axle could run easily, and no axial gap, the way is to add or reduce the gaskets
under the bearing cap.
Ⅳ. No-Load Test
5.5 Maintenance
At the same time, the other parts should be maintenance、check and replace
The replace of the gear oil should be taken at the third-stage maintenance .The replaced
gear oil should let out when it still hot, and watch out the oil has the junk or not. If there is,
remove the drop box's cover and check. When the washed oil let out, put back the plug, use
light diesel 1/3 total quantity. Or the Rerense with 5% engine oil injection. Then runs the
engine some minutes at low speed, (Engaging the front axle is forbidden.) and then stop the
engine. Let out the waste oil; inject the new gear oil at the standard. Also, the above
detergent additive could be spray into the box by the jet gun.
Ⅵ. Lubrication
The lubrication oil is required heavy load gear oil 75W/90(API GL-5), the quantity is
16L(4.224Gallons)
Lubrication points and lubrication period for gear box see following table.
Oil
Methods lubricant Lubrication points period
site
Forced
A 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
NO.3
Grease
B lithium-base Reserve oil in box Often lubricate when working
nipple
lubrication oil
Forced
C 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
D 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
E 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
F 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
G 75W/90 Splash oil Often lubricate when working
lubrication
Forced
H 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Forced
I 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
NO.3
Grease
J lithium-base Reserve oil in box Often lubricate when working
nipple
lubrication oil
Forced
K 75W/90 Oil circuit on the box body Often lubricate when working
lubrication
Ⅷ. Common Troubleshooting
Item Cause Resolve
Repair by welding or replace with the new
1 Over wear of the gear
one
Repair by welding or replace with the new
2 Over wear of the multiple spline keys
one
3 The irregular wear of the bearing Replace with the new one
6 The disengagement didn't work well Remedies the ball seat, replace the ball
9.1 Bearing
Ⅹ.Attached drawings
No. Name Code Qty No. Name Code Qty No. Name Code Qty
1 Plug screw FD140-33 6 40 Bolt M5X20 GB5781-86 6 79 Spring washer 24 GB93-87 6
2 Sealing cushion 1 41 Bearing cover FD100B-15 1 80 Pipe end joint QJKT-2J4-Z4 Z1/8" 5
3 Oil filter WU-25X180-J 1 42 Oil sealPD12X25X10 HG4-692-67 1 81 Nameplate FD100B-24 1
4 Reducer union FD100B-01 1 43 Shaft FD100B-16-00 1 82 Bolt FD140-48 4
5 Pipe end joint QJKT-2J4-Z15 Z3/4" 2 44 Sensor IE472 1 83 Oil drip pan FD100B-25-00 2
6 Bolt M8X19 GB5781-86 4 45 Cover JJX140-33-03-00 1 84 Air core bolt FD140-44 4
7 Spring washer 8 GB93-87 4 46 Spring washer 12 GB93-87 6 85 Fuel-injection pipe FD100B-26 2
8 Output shaft FD100B-02 3 47 Bolt M12X29 GB5781-86 6 86 Straight joint QJKT-2J2-8 M18X1.5 2
9 Input shaft II FD100B-03 1 48 Sealing plate 1 87 Copper pipe L=3.5 1
10 Gear Z=46 m=8 FD100B-04 2 49 Joint I FD100B-34 2 88 Oil dipstick FD140-38-00 1
11 Bolt M8X23 GB5781-86 6 50 Bearing1507 GB281-84 3 89 Sealing plate 1
12 Spring washer 8 GB93-87 6 51 Shift yoke FD100B-17 3 90 O sealing ring 25X3.55 GB3452.1-82 3
13 Center shaft FD100B-05 1 52 Shift yoke sleeve FD100B-18 3 91 Gear change lever FD100B-27 3
14 Bearing cover FD100B-06 1 53 Bearing cover FD100B-19 3 92 Nut M20X1.5 GB6171-86 3
15 stop plate FD100B-07 1 54 Oil seal130X160X15 BAMX7 4 93 Spring washer 10 GB93-87 6
hexagon socket head cap
16 Joint III FD100B-36 2 55 Flange FD140-06 4 94 GB70-85 6
screw M10X23
17 Sealing plate 1 56 Shaft sleeve FD140-09 4 95 Shaft sleeve I FD100B-28 1
18 Gear Z=47 m=8 FD100B-08 1 57 Bolt M8X22 GB5781-86 18 96 deep groove ball bearing 107 GB276-89 62X35X14 2
19 Bearing cover FD100B-09 1 58 Spring washer 8 GB93-87 18 97 Bearing cap FD100B-29 1
20 Bolt M10X27 GB5781-86 10 59 Sealing plate 3 98 Copper pipe L=1.2m 1
21 Spring washer 10 GB93-87 10 60 Shift yoke base FD100B-20-00 3 99 Gear pump CBW-F306-CFP 1
Spring stop collar for
22 Stop plate FD140-07 3 61 GB894.1-86 3 100 Shaft FD100B-30 1
shaft 105
23 Key 32X88 FD140-25 4 62 Sahft sleeve Ⅲ FD100B-21 3 101 Key FD100B-31 1
24 Input shaft I FD100B-10 1 63 Bolt M12X40 GB5781-86 18 102 Shaft sleeve II FD100B-32 1
25 Sealing plate 1 64 Spring washer 12 GB93-87 18 103 Spring washer 8 GB93-87 4
26 Case body FD100B-11-00 1 65 Sealing plate 3 104 Bolt M8X29 GB5781-86 4
27 Case cover FD100B-12 1 66 Pressure gage(0.4Mpa) 1 105 Sealing plate 1
28 Bolt M8X23 GB5781-86 20 67 Oil separater FD100B-22 1 106 Sealing plate 1
29 Spring washer 8 GB93-87 20 68 Pipe end joint QJKT-2J1-Z4 Z1/8" 7 107 Elastic damping ring 35 GB894.1-86 2
30 Sealing plate 1 69 Pipe end joint QJKT-2J1-Z15 Z3/4" 1 108 Pinion FD100B-33 1
31 Spring stop collar 200 GB893.1-86 6 70 Gas cap EF1-25 1
32 Bearing 42222E GB283-87 9 71 Bolt M4X15 GB5781-86 4
33 Shaft sleeve I FD100B-13 3 72 Gear change device FD100B-23-00 1
34 Iron ball φ12 6 73 Pump joint flange II FD140-42 1
35 Spring FD140-15 3 74 Pump joint flange I FD140-41 1
36 Key 32X73 FD100B-14 2 75 Joint II FD100B-35 1
37 Bolt M8X24 GB5781-86 4 76 Three way Pipe end joint QJKT-3J-Z15 Z3/4" 1
38 Spring washer 8 GB93-87 4 77 Nut M24 GB6170-86 6
39 Spring washer 5 GB93-87 4 78 Bolt M24X100 GB5781-86 6